Design Engineer

Posted Tuesday, January 13, 2026 at 7:00 AM

Suncast Corporation is the leading US-based designer, manufacturer, and distributor of high-quality resin products for the home and industrial markets. A privately held company headquartered in Western Chicago, Illinois, Suncast prides itself on 35 years of innovation and sustainability across a wide range of product categories with materials proudly sourced in the USA. Everything we do is supported by the strength and ingenuity of American workers and we are committed to helping families across the country make the most of their unique spaces.

We utilize state-of-the-art machinery and innovative manufacturing techniques to consistently engineer products of the highest possible quality.

The Design Engineer is responsible for taking a product concept and developing it into a finished product. He or she must consider the manufacturing processes and materials we use  manufacturing process and materials must meet the target cost and margin criteria. Design Engineers will use a CAD system extensively. The Suncast design engineering process is team-based. Several engineers may work on a single product together.

Most of the product design work is for injection and blow-molded consumer products. Most assembly is without the use of mechanical fasteners, although metal tubing or similar materials may be used for reinforcement. Suncast also manufactures products using profile extrusion.

• The Design Engineer will develop an overall assembled product design using solid modeling techniques and the drawings and models from the senior product designer. Meet marketing, product, and cost criteria. Use a PC-based CAD system to complete development.
• Work from the approved assembly design to develop components within the assembly.
• Perform finite element analysis at various stages of product development to determine if the design will meet performance criteria.
• Review tooling designs and production methods with the tool engineering group to develop tools for thermoplastic injection molding and profile extrusion. Suggest design modifications to improve productivity.
• The Design Engineer will review product designs with industrial engineering and automation engineering to ensure that the proper assembly processes and equipment are developed for the product.
• Work with quality assurance department to develop appropriate tests for mechanical testing based on design intent.
• Work closely with production and other engineering groups to eliminate problems, improve productivity, and decrease costs during the first production runs.
• Ensure that the product designs meet the packaging intent during packaging development.
• Ensure the product bill of materials and the cost build-up are accurate before the first pilot or production run.
• Assist with model and prototype building. These models may be made from materials such as foam core, wood, and plastic. Processes such as RTV molds may be used.
• Estimate initial component and product cost.
• The Design Engineer will evaluate product design and determine materials to be used. Consider factors such as function, production, and cost criteria.
• Stay informed of new technology, methods, and materials within the field.
• Support and comply with all Suncast safety policies, quality standards, and housekeeping methods at all times. Suncast policies have been developed to ensure compliance with employee law.

To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

• Associate’s degree in CAD or Engineering plus one to three years of experience desired. A bachelor’s degree in mechanical engineering is a plus. Course work or experience in plastic part design is desired.
• Ability to read, analyze, and interpret general business periodicals, professional journals, technical procedures, or governmental regulations. Ability to effectively communicate with and respond to questions from…